Suggested Tools:

• Sockets: 10, 12, 14, & 17 mm• Combination Wrenches: 10,12,14,17,19 22 & 24 mm• 3/8 Ratchet and Extension (or 24 mm tool) for drain

and fill plug removal.• Power Hand Drill: 1/4”• Magnetic Pick-up Tool• Twin Post Lift (or Floor Jack and (2) Safety Stands)• Under Hoist Safety Stand• Loctite®: Blue (Optional)• 1 Qt of 75W90 Gear Oil (Optional)

CAUTION: Safety glasses should be worn at all times when working with vehicles and related tools and equipment.

86-95 Suzuki Samurai HD Transfer Case Mount (SKU# STC-EOS)

Installation Instructions

Revised 4/11/14

Suzuki Samurai Transfer Case Cradle Parts Identification & Kit Content

Passenger Side Arm

Backbone

Driver Side Arm

Transfer Case Mount

Skid Plate

Check to make sure the kit is complete and that no parts are missing. If anything is missing, please contact Low Range Off-Road at 801-805-6644 or Email us at sales@lowrangeoffroad.com

Step 3Remove the interior shifter boot by removing the (4) phillips screws.

Step 2Place the transfer case shifter in NEUTRAL. Then remove the shift knob by twisting in a counter-clockwise direction.

Note: If the knob is hard to loosen, it may be helpful to place a rag over the knob for protection and loosen it with channel lock pliers.

Step 1Position' a' pan' under' the' drain' plug.''

Remove'the'drain'plug'using'a'24'mm'box'

end'wrench' (or' a' 3/8”' extension' if' you'

have'the' internal' square'plug).' ' This'is' a'

good' time' to' change' the' transfer' case'

Eluid' if' it' needs' changing.' ' In' addition,'

draining'the' Eluid'will'make' the' job'a' lot'

cleaner.' ' However,' draining' the' Eluid' is'

not' required.' ' This' job' can' be' done'

without'draining'the'Eluid'if'you'are'very'

careful.

Picture showing hard-to-remove shift knob removal.

Drain Plug

A new shift knob can be purchased on our web site. Click HERE for more information on this and other Samurai T-Case products.

Step 7Depress the lever guide and turn 1/8th turn, counterclockwise. See Figure A for a clearer view.

Note: We found this easier from under the vehicle but could be done from the top.

Step 6Slide the lower shifter boot off the top of the shifter handle.

Lever Guide

Step 5Remove the lower shifter boot with your fingers.

This picture shows a transfer case removed from the vehicle to provide you with a clearer view.Step 4

Slide the boot off the top of the shift lever.

Step 10

Disconnect' the' 4WD' indicator' light'

connector.

Step 9Disconnect' the' speedometer' cable' by'

removing' the'bolt'using'a'10'mm'socket.''

Once' the' bolt' is' removed' pull' the' cable'

out.

4WD Indicator Light Connector

Step 8Remove the lever from the transfer case by pulling upward.

Illustration showing shift lever guide removal procedure.

Speedometer Retainer Bolt

Figure A

Step 11Disconnect' the' rear' propeller' shaft'

(output' to' rear' differential)' from' the'

transfer' case' by' removing' the' 4' bolts'

using'a'12'mm'socket'and'12'mm'box'end'

wrench.' ' It' may' be' necessary' to' hit' the'

drive'line'with'a'dead'blow'hammer'if'the'

propeller'shaft'does'not'disconnect'easily.

Tech TipDisconnect' the' wire' connector' by' lifting'

up' on' the' tab' and' pulling' the' two'

connectors'apart.

Step 12Swing' the' rear'propeller' shaft' aside' and'

support'it'as'shown.

Note:' 'Do' not'remove'this'shaft'from'the'

vehicle.

Step 13Disconnect' the' front' output' propeller'

shaft' (output' to' the' front' differential)'

from'the' transfer'case'by' removing' the'4'

bolts' using' a' 12'mm' socket' and'12'mm'

box'end'wrench.

Lift Tab with Thumb

Rear Output Propeller Shaft

Front Output Propeller Shaft

Rear Output Propeller Shaft

Step 15Disconnect'the'front' input'propeller'shaft'

(input' from' the' transmission)' from' the'

transfer' case' by' removing' the' 4' bolts'

using'a'12'mm'socket'and'12'mm'box'end'

wrench.

Step 14Push'the'shaft'forward'(it'will' telescope)'

and' let' it' rest' on' the' crossmember'

support'as'shown.

Note:' 'Do' not'remove'this'shaft'from'the'

vehicle.''''''

Front Input Propeller Shaft

Front Output Propeller Shaft

Slip Yoke

Front Input Propeller Shaft

To Transfer Case

From TransmissionStep 16

Remove'the'shaft'by'letting'the'rear'drop'

down'and'pulling'it'toward'the'rear'of'the'

vehicle.' ' The'front' of'this'propeller'shaft'

has' a' slip' yoke' (See' Figure' B)' and' will'

easily'slide'out'of'the'transmission.

Figure B

Step 18Lift' up'on' the' transfer' case' until' the' (3)'

mount' studs' clear' the' supports.' ' Then'

move' the'entire' transfer' case'toward'the'

rear' of' the' vehicle.' ' When' it' clears' the'

transfer' case'supports,' lower' the' case' to'

the'Eloor.

Caution:''This'transfer'case'is'a'bit'heavy.''

So' if' you' did' not' have' your' “Wheaties”'

this' morning' you' may' want' to' get'

someone'to'assist'you.

Step 20Remove' the' driver' side' bracket' by'

removing' the' 4' bolts' using' a' 12' mm'

socket.

Note:' This' bracket'will' not'be'used'with''

new'cradle'kit.

Step 17Remove'the'(3)'transfer' case'mount'nuts'

using'a'14'mm'socket.

Stud

Suppor

Step 19Remove' the' (3)' transfer' case'mounts' by'

removing'the'nuts'using'a'14'mm'socket.

Note:' 'Save'these'(3)'mounts.'They'will'be'

used'with'the'new'cradle.

Mount

Step 22 Remove the 4WD indicator light switch with a 22 mm combination wrench.

Step 23Remove the steel ball using a magnet.

Step 24Set these two components (the ball and switch) aside. They will be reused later.

Step 21If' the' Eluid' has' been' drained,' turn' the'

transfer' case' over' and' remove' the'

passenger' side' bracket' by' removing' the'

(4)' bolts' using' a' 12' mm' socket.' ' This'

bracket' will' not' be' used' with' the' new'

cradle'kit.

Caution:'If'the'Eluid'has'not'been'drained,'

this' step' will' have' to' be' done' with' the'

transfer'case'upright.'

Step 26Remove the nine case bolts indicated by the RED arrows. Do not remove the other 4 case bolts indicated by BLACK arrows.

Step 25Place the transfer case on a suitable work bench.

Note: The transfer case we removed had a few problems. So we pulled a freshly rebuilt cases off the shelf to use for these instructions.

Step 27Locate the 9 cap bolts and lock washers that look like these. There should be 6 short and 3 long bolts with lock washers for each bolt.

• 6 - 8X1.25X45mm Bolts• 3 - 8X1.25X55mm Bolts• 9 - 8 mm Lock Washers

Step 26 ContinuedCaution: Be gentle with the transfer case once the bolts are removed. Rough handling could cause the case halves to separate resulting in a fluid leak after the cradle installation is complete.

6 Short Cap Bolts

3 Long Cap Bolts

55 mm45 mm

Step 28Position the cradle backbone as shown above.

Step 29Caution: Bolt length positioning is critical.

Install the cap bolts and lock washers supplied with the cradle as shown. Long bolt placement is indicated by the blue arrows, and short bolt placement is indicated by the red arrows. DO NOT tighten them yet.

Note: All bolts and nuts that will be used during the installation of this cradle are to be left loose until all the bolts and nuts have been installed. After all the bolts and nuts have been installed, the tightening sequence will be explained. Tightening bolts and nuts out of sequence may result in cross-threading, case damage and cradle part misalignment.

Step 30Position the passenger side arm as shown.

Passenger Side Arm

Cradle Backbone

Step 31Install the (2) remaining bolts and lock washers in the positions indicated by the arrows. Remember blue is long and red is short. Also, remember to leave them loose.

Step 32Align the 4 holes in the passenger side arm with the holes in the transfer case.

Step 34Locate the (2) larger flange bolts, (2) flat washers and (2) Nylock nuts.

• 2 - 10X1.0X25 mm Flange Bolts• 2 - 10X1.0 mm Nylock® Nuts• 2 - 10 mm Flat Washers

Step 33Install the (4) small flange bolts and leave them loose as well.

• 4 - 8X1.0X20 mm Flange Bolts

Step 35Position the driver side arm as shown and install the two large flange bolts as shown.

Step 35 Continued

Install the flat washers and Nylock® nuts on the bolts.

Step 36Install the (4) small flange bolts as shown. Leave these loose as well.

• 4 - 8X1.0X20 mm Flange Bolts

Driver Side Arm

At this point all the cradle attaching bolts and nuts should be installed and left loose.

Step 38Tighten and torque all (9) backbone/case bolts in a chris-cross pattern. (9.5 to 16.5 ft. lbs.)

Step 39Tighten and torque the passenger side arm-to-case bolts. (13.5 to 20 ft. lbs.)

Note: The top two bolts will have to be tightened with an end wrench to an estimated torque. A socket and torque wrench will not fit.

Step 37Remove each of the 9 backbone/case bolts, one by one, apply blue loctite® to the threads and reinstall them.

Note: This step is optional but we do strongly recommend it.

Bolt Tightening Sequence

Step 40Tighten and torque the driver side arm-to-backbone nuts. (30 to 35 ft. lbs.)

Note: The tools needed are 17 mm for the nut and 14 mm for the bolt.

Step 43Install the 4WD indicator switch and tighten. (12 to 16.5 ft. lbs.)

Step 42Insert the 4WD indicator ball in the hole as shown.

Step 41Tighten and torque the driver side arm-to-case bolts. (13.5 to 20 ft. lbs.)

Step 44Install mounts #1 and #2 on the passenger side arm as shown, and tighten the nuts. (18.5 to 25 ft. lbs.)

Note: Be sure there is a lock washer under each nut.

#1#2

Note: There is only one mount supplied with this kit. You will need to use all three of the original mounts that you removed from the brackets earlier. If you are interested in purchasing new quality OEM mounts click HERE to see what we offer. Mount Location and Numbering on Vehicle

#2#3

#4#1

Mount Locations and Numbering on Cradle

#1#2

#4

#3

Tech TipAll mounts are interchangeable. We numbered them to help make these instructions clearer.

Transfer Case Mount Installation

Step 45Install mount #3 in the location shown by the arrow. Tighten the nut to 18.5 to 25 ft. lbs.

Note: Make certain that the pin in the mount aligns with the hole in the support on this and all other mounts.

Install Mount #3 Here

Step 44 ContinuedMake certain that the locater pin on the mount aligns with the hole in the arm on this and all other mounts.

Locater Pin

HoleWarning:

If any of the mounts do not have locator pins, they are not Suzuki OEM mounts. Do not use aftermarket mounts with this cradle. They will not hold up. To see a video about OEM vs. Aftermarket mount testing, click HERE.

Locater Pin

Tech Tip:Have'an'under'hoist' jack'stand,' or'a'Eloor'

jack' if' you' are' working' on' jack' stands,'

close' at' hand.' ' Also,' it' is' very'helpful' to'

have'an'assistant' help'with'this' phase'of'

the'installation'even'if'you'did'have'your'

“Wheaties”' this' morning.' The' transfer'

case'is'quite'a'bit'heavier'now,'than'it'was'

when'it'was'removed.

Step 46Being' very' careful,' lift' the' transfer' case''

and'position' it' such' that' both'passenger'

side'mount' studs'(mounts'#1'and'#2)'sit'

into' their' proper' holes' in' the' frame'

support.'

Transfer Case Installation

Step 47Then'raise' the' drivers' side' of' the' cradle'

into' position' and' support' it' with' the'

under'hoist'jack'stand'or'a'Eloor'jack.

Step 48Using'the'holes'in'the'driver'side'arm'as'a'

guide,' drill' a' hole' in' the' cross' member'

support' using' the' “Y”' size' drill' bit'

supplied'in' this'kit.' 'This'hole,' as'well'as'

the' hole' drilled' in' the' next' step,' will' be'

used'to'install'mount'#4.

Cross Member Support

Mount #1

Mount #2

Step 49Again,' using'the'hole' 'in'drivers'side'arm'

as'a'guide,'drill'a'second'hole'in'the'cross'

member' using' the'1/4”'drill' bit'supplied'

in'this'kit.

Step 50Lower the transfer case slightly and insert mount #4. Make sure the pins in the mount align with the hole in the cross member as well as the hole in the support arm.

Note: This 4th mount is supplied with the cradle kit.

Step 51Raise the transfer case into position. As you raise the transfer case, check to see that both driver side mounts, mounts #3 and #4, are aligned properly.

Step 52Install the lock washers and nuts on the top and bottom of mount #4 and tighten. (18.5 to 25 ft. lbs.)

Step 56Install the transfer case skid plate and tighten the (3) serrated flange bolts. (25-30 ft. lbs.)

3-10X1.5X 30 mm

Step 55If the transfer case was drained at the beginning, it will have to be refilled. First, be sure the drain plug (plug #1) is installed and tight. Then remove the fill and check plug (Plug #2). Pump fluid into the hole until it runs out. Once fluid runs out, quickly reinstall the plug and tighten it. Do not over-tighten either plug. (Torque spec is 13.5 to 20 ft. lbs.)

Note: We recommend using SAE 75W90 Gear Oil. Refill capacity is 1 quart.

Step 53Install the lock washer and nut on mount #3 and tighten. (18.5 to 25 ft. lbs.)

Step 54Install the lock washers and nuts on both passenger side mounts, #1 and #2, and tighten. (18.5 to 25 ft. lbs.)

Warning: Over-tightening of plug #2 can interfere with internal shifting mechanisms result ing in the shif ter popping out of gear when in the 4H position.

Serrated Flange Bolt

Mount #2

Mount #1

Step 59Reconnect the rear output shaft and tighten the bolts. (17 to 21.5 ft. lbs.)

Step 57Reconnect the 4WD indicator connector.

Note: Push it together until it snaps.

Step 58Reconnect the speedometer cable and install the bolt.

Note: This bolt hole is easily stripped. It only needs to be snug.

Step 60Install the input propeller shaft, by inserting the slip yoke (See Figure C) into the transmission and connecting the other end of the shaft to the transfer case. Tighten the bolts. (17 to 21.5 ft. lbs.)

Slip Yoke

Input Propeller Shaft

Figure C

To Transfer Case

From Transmission

Step 61Connect the front output shaft and tighten the bolts. (17 to 21.5 ft. lbs.)

Step 62If you are working with the vehicle on a twin post lift, lower the vehicle to the floor.

Tech Tip:If not done previously, we strongly recommend you replace the Transfer Case Shifter Sheet. This part, when installed, can make an enormous difference in transfer case shifter feel and performance. Click HERE for more information on our Transfer Case Shifter Sheets.

Step 63Reinstall the shift lever.

Step 64Align the grooves in the shifter guide with the pins that are inside the shifter cavity.

Note: Inspect the shifter guide for wear and replace it if needed. This and other parts can be found on our web site. Click HERE for more information.

Shifter GuideCommon Wear Point

Step 65Depress the lever guide and rotate clockwise until it locks.

Note: Move transfer case shifter handle into each position (4L, N, 4H, 2H) verifying correct installation.

Step 66Reinstall the lower boot.

Note: Final positioning of the boot may be easier from under the vehicle.

Step 67 Reinstall the upper boot and install the 4 phillips screws.

Step 68Reinstall the shift knob.

Note: If the lower boot or upper boot is damaged or cracked we recommend replacement. If you are interested in seeing what is available through our we site, click HERE for more information.

As always, If you experience any difficulty during the installation of this product please contact Low Range Off-Road Technical Support at 801-805-6644 M-F 8am-5pm MST. Thank you for purchasing from Low Range Off-Road.

These instructions are designed as a general installation guide. Installation of many Low Range Off-Road parts requires specialized skills such as metal fabrication, welding and mechanical trouble shooting. If you have any questions or are unsure about how to proceed, please contact our shop at 801-805-6644 or seek help from a competent fabricator. Using fabrication tools such as welders, torches and grinders can cause serious bodily harm and death. Please operate equipment carefully and observe proper safety procedures.

Rock crawling and off-road driving are inherently dangerous activities. Some modifications will adversely affect the on-road handling characteristics of your vehicle. All products sold by Low Range Off-Road are sold for off road use only. Any other use or application is the responsibility of the purchaser and/or user. Some modifications and installation of certain aftermarket parts may under certain circumstances void your original dealer warranty. Modification of your vehicle may create dangerous conditions, which could cause roll-overs resulting in serious bodily injury or death. Buyers and users of these products hereby expressly assume all risks associated with any such modifications and use.

Revised 10/29/12 © Copyright 2012 Low Range Off-Road, LC      All Rights Reserved